Patents by Inventor Kenji Otake
Kenji Otake has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 9287033Abstract: A magnetic material contains multiple metal grains constituted by soft magnetic alloy and oxide film formed on a surface of the metal grains, which soft magnetic alloy includes Fe and a metal element that oxidizes more easily than Fe, wherein the magnetic material forms a grain compact having first bonding parts where adjacent metal grains are contacted and directly bonded together, second bonding parts where adjacent metal grains are bonded together via the oxide film formed around the entire surface of said adjacent metal grains other than the first bonding parts, and voids formed in an area other than the first and second bonding parts and surrounded by the oxide film.Type: GrantFiled: January 23, 2014Date of Patent: March 15, 2016Assignee: TAIYO YUDEN CO., LTD.Inventors: Hitoshi Matsuura, Kenji Otake
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Patent number: 9287026Abstract: An object is to provide a magnetic material and coil component offering improved magnetic permeability and insulation resistance, while also offering improved high-temperature load, moisture resistance, water absorbency, and other reliability characteristics at the same time. A magnetic material that has multiple metal grains constituted by Fe—Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe), as well as oxide film constituted by an oxide of the soft magnetic alloy and formed on the surface of the metal grains, wherein the magnetic material has bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, as well as bonding parts where metal grains are directly bonded together in areas having no oxide film, and resin material is filled in at least some of the voids generating as a result of accumulation of the metal grains.Type: GrantFiled: April 18, 2012Date of Patent: March 15, 2016Assignee: Taiyo Yuden Co., Ltd.Inventors: Hitoshi Matsuura, Masahiro Hachiya, Kenji Otake
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Patent number: 9165705Abstract: A laminated inductor having an internal conductor forming region, as well as a top cover region and bottom cover region formed in a manner sandwiching the internal conductor forming region between top and bottom; wherein the internal conductor forming region has a magnetic part formed with soft magnetic alloy grains, as well as helical internal conductor embedded in the magnetic part; and at least one of the top cover region and bottom cover region (or preferably both) is/are formed with soft magnetic alloy grains whose average grain size is greater than that of grains in the internal conductor forming region including the soft magnetic alloy grains constituting the magnetic part.Type: GrantFiled: November 1, 2013Date of Patent: October 20, 2015Assignee: TAIYO YUDEN CO., LTD.Inventors: Hitoshi Matsuura, Takayuki Arai, Kenji Otake
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Patent number: 9093213Abstract: A common mode choke coil exhibiting greater reliability against moisture load includes a nonmagnetic layer made of glass, magnetic layers placed in a manner sandwiching the nonmagnetic layer, and two or more coil conductors embedded in a base material constituted by the nonmagnetic layer and magnetic layers, wherein Mg segregation is present in the nonmagnetic layer and the Mg segregation accounts for 0.5 to 16 percent of the total area as observed on an electron micrograph of a section of the nonmagnetic layer, while the size of Mg segregation is preferably 0.2 to 10 ?m.Type: GrantFiled: January 23, 2014Date of Patent: July 28, 2015Assignee: TAIYO YUDEN CO., LTD.Inventors: Keiko Shiroki, Takashi Nakajima, Kenji Otake
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Patent number: 9030285Abstract: A magnetic material suitable for a coil component has multiple metal grains constituted by Fe—Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe) and oxide film formed on the surface of the metal grains, wherein such magnetic material includes a grain compact having bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, and bonding parts where metal grains are directly bonded together in areas where oxide film does not exist. The magnetic material is capable of improving both insulation resistance and magnetic permeability.Type: GrantFiled: October 13, 2011Date of Patent: May 12, 2015Assignee: Taiyo Yuden Co., Ltd.Inventors: Hitoshi Matsuura, Kenji Otake
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Patent number: 9007159Abstract: A coil-type electronic component having a coil inside or on the surface of a base material is characterized in that the base material of the coil-type electronic component is constituted by a group of soft magnetic alloy grains inter-bonded via oxide layers, multiple crystal grains are present in each soft magnetic alloy grain, and the oxide layers preferably have a two-layer structure whose outer layer is thicker than the inner layer.Type: GrantFiled: December 7, 2012Date of Patent: April 14, 2015Assignee: Taiyo Yuden Co., Ltd.Inventors: Masahiro Hachiya, Atsushi Tanada, Kenji Otake, Kiyoshi Tanaka, Tetsuyuki Suzuki
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Patent number: 8896405Abstract: A coil-type electronic component having a coil inside or on the surface of a base material, characterized in that the base material of the coil-type electronic component is constituted by a group of soft magnetic alloy grains whose main ingredients are iron, silicate and chromium, and that an oxide layer is formed on the surface of each soft magnetic alloy grain, where the oxide layer is produced as a result of oxidization of the grain and has more chromium than the alloy grain, and this oxide layer has a two-layer structure constituted by an inner layer whose main ingredient is chromium oxide and an outer layer whose main ingredient is iron-chromium oxide, and the outer layers of soft magnetic alloy grains are inter-bonded.Type: GrantFiled: October 26, 2012Date of Patent: November 25, 2014Assignee: Taiyo Yuden Co., Ltd.Inventors: Masahiro Hachiya, Atsushi Tanada, Kenji Otake, Kiyoshi Tanaka, Tetsuyuki Suzuki
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Patent number: 8866579Abstract: A laminated inductor offers higher magnetic permeability, high inductance, low resistance and high rated current, while also supporting downsizing of device, by using a soft magnetic alloy as the magnetic material. Provided is a laminated inductor, comprising: an internal conductor forming area and a top cover area and a bottom cover area formed in a manner sandwiching the internal conductor forming area from above and below, wherein the internal conductor forming area has a magnetic material part formed by soft magnetic alloy particles, and internal conductors buried in the magnetic material part, and at least one of the top cover area and bottom cover area is formed by soft magnetic alloy particles exhibiting a two-peak particle size distribution curve (based on count).Type: GrantFiled: November 16, 2012Date of Patent: October 21, 2014Assignee: Taiyo Yuden Co., Ltd.Inventors: Masahiro Hachiya, Takayuki Arai, Kenji Otake
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Publication number: 20140266545Abstract: A common mode choke coil exhibiting greater reliability against moisture load includes a nonmagnetic layer made of glass, magnetic layers placed in a manner sandwiching the nonmagnetic layer, and two or more coil conductors embedded in a base material constituted by the nonmagnetic layer and magnetic layers, wherein Mg segregation is present in the nonmagnetic layer and the Mg segregation accounts for 0.5 to 16 percent of the total area as observed on an electron micrograph of a section of the nonmagnetic layer, while the size of Mg segregation is preferably 0.2 to 10 ?m.Type: ApplicationFiled: January 23, 2014Publication date: September 18, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Keiko SHIROKI, Takashi NAKAJIMA, Kenji OTAKE
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Publication number: 20140225703Abstract: A magnetic material includes a grain compact in which metal grains having oxide films are compacted, wherein the metal grains are constituted by Fe—Si-M soft magnetic alloy (where M represents a metal element that oxidizes more easily than iron), the metal grains in the grain compact are mutually bonded with adjacent metal grains by inter-bonding of their oxide films, and at least some of this bonding of oxide films takes the form of bonding of crystalline oxides, or preferably at least some of the bonding of oxides is based on continuous lattice bond. A coil component has a coil on an interior or surface of an element body wherein the element body uses the magnetic material.Type: ApplicationFiled: January 5, 2012Publication date: August 14, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Kenji Otake, Hitoshi Matsuura
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Patent number: 8797136Abstract: A laminated common-mode choke coil offering higher insulation reliability has a glass ceramic layer, two spiral internal conductors facing each other and sandwiching the glass ceramic layer in between, and insulation layers sandwiching the two internal conductors, wherein the glass ceramic layer contains segregated Al regions and the maximum dimension t1 of each segregated Al region in the glass ceramic layer, in the layer-thickness direction, is no more than 80% of the distance t0 between the two internal conductors.Type: GrantFiled: December 17, 2012Date of Patent: August 5, 2014Assignee: Taiyo Yuden Co., Ltd.Inventors: Takashi Nakajima, Mika Tamanoi, Kenji Otake
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Publication number: 20140139311Abstract: A magnetic material contains multiple metal grains constituted by soft magnetic alloy and oxide film formed on a surface of the metal grains, which soft magnetic alloy includes Fe and a metal element that oxidizes more easily than Fe, wherein the magnetic material forms a grain compact having first bonding parts where adjacent metal grains are contacted and directly bonded together, second bonding parts where adjacent metal grains are bonded together via the oxide film formed around the entire surface of said adjacent metal grains other than the first bonding parts, and voids formed in an area other than the first and second bonding parts and surrounded by the oxide film.Type: ApplicationFiled: January 23, 2014Publication date: May 22, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Hitoshi MATSUURA, Kenji OTAKE
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Publication number: 20140132383Abstract: An object is to provide a magnetic material and coil component offering improved magnetic permeability and insulation resistance, while also offering improved high-temperature load, moisture resistance, water absorbency, and other reliability characteristics at the same time. A magnetic material that has multiple metal grains constituted by Fe—Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe), as well as oxide film constituted by an oxide of the soft magnetic alloy and formed on the surface of the metal grains, wherein the magnetic material has bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, as well as bonding parts where metal grains are directly bonded together in areas having no oxide film, and resin material is filled in at least some of the voids generating as a result of accumulation of the metal grains.Type: ApplicationFiled: April 18, 2012Publication date: May 15, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Hitoshi Matsuura, Masahiro Hachiya, Kenji Otake
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Publication number: 20140055224Abstract: A laminated inductor having an internal conductor forming region, as well as a top cover region and bottom cover region formed in a manner sandwiching the internal conductor forming region between top and bottom; wherein the internal conductor forming region has a magnetic part formed with soft magnetic alloy grains, as well as helical internal conductor embedded in the magnetic part; and at least one of the top cover region and bottom cover region (or preferably both) is/are formed with soft magnetic alloy grains whose average grain size is greater than that of grains in the internal conductor forming region including the soft magnetic alloy grains constituting the magnetic part.Type: ApplicationFiled: November 1, 2013Publication date: February 27, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Hitoshi MATSUURA, Takayuki ARAI, Kenji OTAKE
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Publication number: 20140049348Abstract: A magnetic material suitable for a coil component has multiple metal grains constituted by Fe—Si-M soft magnetic alloy (where M is a metal element that oxidizes more easily than Fe) and oxide film formed on the surface of the metal grains, wherein such magnetic material includes a grain compact having bonding parts where adjacent metal grains are bonded together via the oxide film formed on their surface, and bonding parts where metal grains are directly bonded together in areas where oxide film does not exist. The magnetic material is capable of improving both insulation resistance and magnetic permeability.Type: ApplicationFiled: October 13, 2011Publication date: February 20, 2014Applicant: TAIYO YUDEN CO., LTD.Inventors: Hitoshi Matsuura, Kenji Otake
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Patent number: 8610525Abstract: A laminated inductor having an internal conductive wire forming region, as well as a top cover region and bottom cover region formed in a manner sandwiching the internal conductive wire forming region between top and bottom; wherein the internal conductive wire forming region has a magnetic part formed with soft magnetic alloy grains, as well as helical internal conductive wires embedded in the magnetic part and constituted by a conductor; and at least one of the top cover region and bottom cover region (or preferably both) is/are formed with soft magnetic alloy grains whose constituent elements are of the same types as those of, and whose average grain size is greater than that of, the soft magnetic alloy grains constituting the magnetic part in the internal conductive wire forming region.Type: GrantFiled: March 21, 2012Date of Patent: December 17, 2013Assignee: Taiyo Yuden Co., Ltd.Inventors: Hitoshi Matsuura, Takayuki Arai, Kenji Otake
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Patent number: 8558652Abstract: Provided is a laminated inductor having a magnetic body, a conductor part covered in a manner directly contacting the magnetic body, and external terminals provided on the outside of the magnetic body and conducting to the conductor part; wherein the magnetic body is a laminate constituted by layers containing soft magnetic alloy grains, and the soft magnetic alloy grain contacting the conductor part is flattened on the conductor part side.Type: GrantFiled: January 17, 2012Date of Patent: October 15, 2013Assignee: Taiyo Yuden Co., Ltd.Inventors: Takayuki Arai, Hitoshi Matsuura, Kenji Otake
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Patent number: 8525630Abstract: A laminated inductor having a laminate structure constituted by magnetic layers and internal conductive wire-forming layers, wherein the magnetic layer is formed by soft magnetic alloy grains, the internal conductive wire-forming layer has an internal conductive wire and a reverse pattern portion around it, and the reverse pattern portion is formed by soft magnetic alloy grains whose constituent elements are of the same types as those of, and whose average grain size is greater than that of, the soft magnetic alloy grains constituting the magnetic layer.Type: GrantFiled: March 23, 2012Date of Patent: September 3, 2013Assignee: Taiyo Yuden Co., Ltd.Inventors: Tomomi Kobayashi, Hitoshi Matsuura, Takayuki Arai, Masahiro Hachiya, Kenji Otake
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Publication number: 20130176098Abstract: A magnetic material constituted by a grain compact 1 obtained by shaping metal grains 11 and then heat-treating them in an oxidizing ambience, wherein the metal grains 11 are made of a Fe—Cr—Si alloy and their FeMetal/(FeMetal+FeOxide) ratio as measured before shaping by XPS, with respect to the sum of integral values at the peaks of 709.6 eV, 710.7 eV and 710.9 eV, or FeOxide, and peak integral value at 706.9 eV, or FeMetal, is 0.2 or more.Type: ApplicationFiled: July 11, 2012Publication date: July 11, 2013Applicant: TAIYO YUDEN CO., LTD.Inventors: Hitoshi MATSUURA, Hideki OGAWA, Atsushi TANADA, Kiyoshi TANAKA, Kenji OTAKE
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Patent number: 8427265Abstract: A laminated inductor includes a laminate constituted by multiple magnetic material layers, and coil conductors formed in a spiral pattern in the laminate. The magnetic material layers are layers of a magnetic material having multiple metal grains constituted by a Fe—Si-M soft magnetic alloy and oxide film formed on the surface of the metal grains. The magnetic material has bonding portions where adjacent metal grains are bonded via the oxide film formed on the respective surfaces of the adjacent metal grains as well as bonding portions of metal grains bonding to each other in areas where no oxide film is present, and at least some of the voids generated by agglomeration of the metal grains are filled with a resin material.Type: GrantFiled: April 20, 2012Date of Patent: April 23, 2013Assignee: Taiyo Yuden Co., Ltd.Inventors: Masahiro Hachiya, Takuya Ishida, Takayuki Arai, Kenji Otake, Hitoshi Matsuura